Abdel-Hakim Bouzid

An Accurate Method of Evaluating Relaxation in Bolted Flanged Connections

Bolted flanged joint assemblies may begin to leak some time following a successful hydrostatic test. One of the reasons is that the gasket experiences a drop in its initial compressive stress due to creep, thermal dilatation, and thermal degradation. The need to pay attention to the relaxation behavior of bolted joints for high-temperature applications is recognized by the ASME Code, but no specific guidelines are given to help engineers, neither at the design nor maintenance levels. This paper deals with the basic analytical tools that have been used to develop a computer program SuperFlange that can be used to make accurate predictions of the relaxation of bolted flanged joints, and hence be able to provide a reasonable leakage assessment over time. A simplified analytical method of relaxation analysis will also be presented. These proposed methods are supported by test results obtained on a real bolted joint fixture and by FE modeling. A strong emphasis will be put on flanged joint rigidity, which is one of the major controlling parameters of relaxation besides the material properties involved.

An Analytical Solution for Evaluating Gasket Stress Change in Bolted Flange Connections Subjected to High Temperature Loading

The tightness of bolted flanged joints subjected to elevated temperature is not properly addressed by flange design codes. The development of an analytical method based on the flexibility of the different joint components and their elastic interaction could serve as a powerful tool for elevated temperature flange designs. This paper addresses the effect of the internal fluid operating temperature on the variation of the bolt load and consequently on the gasket stress in bolted joints. The theoretical analysis used to predict the gasket load variation as a result of unequal radial and axial thermal expansion of the joint elements is outlined. It details the analytical basis of the elastic interaction model and the thermally induced deflections that are used to evaluate the load changes. Two flange joint type configurations are treated: a joint with identical pair of flanges and a joint with a cover plate. The analytical models are validated and verified by comparison to finite element results.

Analytical modeling of the contact stress with nonlinear gaskets

Gasket contact stress and its variation through the gasket width is caused by the rotation of the flange and has an influence on the leakage tightness behavior of bolted flange joints. The future implementation by the ASME of proposed design rules is based on new gasket constants obtained from the ROTT (room temperature tightness) tests conducted on rigid platens. The gasket contact stress distribution needs to be addressed for the purpose of better joint tightness predictions. This paper presents a comprehensive analytical method that predicts the gasket contact stress distribution taking into account the nonlinear mechanical behavior of the gasket material. Based on the flange rotational flexibility, the proposed analytical model that is implemented in the SuperFlange program is supported and validated by numerical FEA and experimental analyses on flange rotations, radial distribution of gasket contact stress, and joint leak tightness.

An Experimental-Numerical Procedure for Stuffing Box Packing Characterization and Leak Tests

The sealing of valve stems is ensured by the traditional systems of packed stuffing boxes. The performance of this type of sealing system, which is also used in rotating equipment, is dependent on the radial contact pressures generated by the packing axial compression. The mechanical behavior of a packing seal is characterized by the transmission ratio of the radial stress over the axial stress known as the lateral pressure coefficient, which is one of the required parameters used to select packing seals. However, the modeling of the packed stuffing box requires the knowledge of other packing seal mechanical characteristics such as compression modulus and Poissons ratio. In this paper, the mechanical characteristics of packing seals are obtained using a hybrid experimental-numerical procedure. The experimental study is carried out on an instrumented stuffing box packing test bench. The tests results of the experiments are coupled to the ones obtained by a finite element simulation of the test rig to determine the packing seal mechanical characteristics. Two packing types are used: one based on Teflon and the other one based on flexible graphite. In addition, leak rates are measured.for different axial compressive stresses and gas pressures in order to estimate the tightness performance of such seals.

The Determination of Load Changes in Bolted Gasketed Joints Subjected to Elevated Temperature

The tightness of bolted flanged joints subjected to elevated temperature is not properly addressed by flange design codes. The development of an analytical method based on the flexibility of the different joint components and their elastic interaction could serve as a powerful tool for elevated temperature flange designs. This paper addresses the effect of the internal fluid operating temperature on the variation of the bolt load and consequently on the gasket stress in bolted joints. The theoretical analysis used to predict the gasket load variation as a result of a temperature change is outlined. It details the analytical basis of the elastic interaction model and the thermally induced deflections that are used to evaluate the load changes. Two flange joint type configurations are treated; a joint with identical pair of flanges and a joint with a cover plate. The analytical models are validated and verified by comparison to finite element results.Copyright

Determination of Gasket Stress Levels During Thermal Transients

The leakage of bolted flange joints at high temperature or during transient thermal shock is a well recognised problem. However, the present pressure vessel design codes do not address the effects of temperature on the integrity of the bolted joint, other than material properties. A research project currently being conducted at Ecole Polytechnique is intended to provide designers with an analytic approach for establishing the effects of thermal loading on the joint sealing ability. This paper is the fourth to be published as part of this research project. The presented analysis method enables the determination of the temperature response of the joint components to a transition in internal fluid temperature. Using this data, the worst case operating scenario may be selected and calculations performed to determine the impact of the temperature transition on the gasket stress levels. The presented analytical method is verified by comparison to finite element analysis and experimental measurement.Copyright

Analytical modeling of hydraulically expanded tube-to-tubesheet joints

The loss of the initial tightness during service is one of the major causes of failure of tube-to-tubesheetjoints. The initial residual contact pressure and its variation during the lifetime of the joint are among the parameters to blame. A reliable assessment of the initial contact pressure value requires accurate and rigorous modeling of the elastoplastic behavior of the tube and the tubesheet during the expansion process. This paper deals with the development of a new analytical model used to accurately predict the residual contact pressure resulting from a hydraulic expansion process. The analytical model is based on the elastic perfectly plastic material behavior of the tube and the tubesheet and the interaction between these two elements of the expanded joint. The model results have been compared and validated with those of the more accurate finite element analysis models. Additional comparisons have been made with existing methods.

Thermally induced deflections in bolted flanged connections

Pressure vessel joints operating at high temperature are often very difficult to seal. The existing flange design methods do not address thermal effects other than the variation of flange material mechanical properties with temperature. It is possible to include the effects of temperature loading in joint analysis, however, presently very few guidelines exist for this type of analysis. This paper outlines the theoretical analysis used for the determination of the steady state operating temperature and deflections in bolted flange joints. It details the theoretical equations necessary to predict the temperature profiles and thermal expansion difference between the joint components necessary for the evaluation of the load redistribution for the two cases of a flange pair and a flange with a cover plate. The results from the theoretical models are verified by comparison to finite element results.

Short term relaxation modeling of valve stem packings

The long term tightness performance of stuffing-box packings, used in valves, is conditioned by the capacity of its sealing material to maintain a contact pressure to a predetermined minimal threshold value. Due to the creep, this contact pressure decreases with time depending on the creep properties and the stiffness of the housing. Assessing relaxation is a key parameter in determining the tightness performance of a valve stem packing over time. An analytical model based on the packing viscoelastic behavior is developed to assess the contact pressures between the packing material and the stem and the housing and their variation with time. In parallel, an axisymmetric 2D finite element model was build to validate and support the analytical model. The valve stem packing relaxation performance is an important design parameter to consider when selecting compression packings.

Creep Modeling in Bolted Flange Joints

Bolted flanged connections are used extensively in the petrochemical and nuclear industries. Under high temperatures, their leakage tightness behavior is compromised due to the loss of load as a result of creep of not only the gasket material but also the bolt and the flange materials. The relaxation of the bolt load and the corresponding loss of the gasket contact stress are not easy to assess analytically and consequently there is no established design calculation procedure. The objective of this paper is to present an analytical method that is part of the SuperFlange program [1] and is capable of predicting the load relaxation in a bolted joint when subjected to flange, bolt and gasket creep. The proposed method is validated by comparison with 3D FE models of different size flanges. In some cases, the relaxation caused by the flange and bolt materials is shown to be significant.Copyright